INTRODUCTION *General Info | This manual is divided into 14 sections. The first page of each sec- tion is marked with a black tab that lines up with its corresponding | thumb index tab on thi | find the firet page, table of contents, 1. A table of contents, © Parts disassembly Disassembly/assembly proct Inspection Testing/troubleshooting. Repair. Adjustments. [— Special Information PETE indicates a strong possibility of seve oF loss of life if instructions are not followed. CAUTION: Indicates a possiblity of personal injury o damage if instructions are not followed. NOTE: Gives helpful information. CAUTION: Detailed descriptions of standard workshops pro- ‘operations are not included. SONAL INJURY, understand that these ty not vehicle safety will be jeopardized. Al information contained in this manual is based on the latest pro- duct information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables, Special Tools Specifications Maintenance Engine 1 | Cooling Fuel and Emissions Pa *Transaxle (Including [ABS }) *Body First Edition 9/91 1314pages HONDA MOTOR CO... LTD. All Rights Reserved Service Publication Office Specification apply to U.S.A. and Canada *Heater and Air Conditioner *Electrical (Including ‘Re sections with * Include SRS components, “special precautions ae required when servicing‘SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “The CIVIC includes # driver bag (US Cars, Caneda: Optional on EXVI, located in the steering wheel hub, as pert of the Supplemental Restraint System (SRS). Information necessary to safely service the SRS.js included in this Service Manual. Items marked * in each sections table of contents include, or are located near SRS com- ponents. Servicing, disassembling or replacing these items will require special cautions and tools, and should ‘therefore be done only by an authorized Honda dealer. ‘© To avold rendering the SRS inoperative, which can lead to personal injury or death in the event of a severe fron- ‘al collision, all maintenance must be performed by an authorized Honda desler. ‘© Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury ‘caused by unintentional activation of the airbag. ‘© AIISRS electrical wiring hamesses are covered with yellow outer insulation and related components are located in the steering column, dash, center console, and dashboard lower panel. Do not use electrical test equipment ‘on these circuitsGeneral Information Chassis and Paint Codes . Identification Number Locations Label Locations .. Lift and Support Points Towing ..... + 1-10 + 1-13Chassis and Paint Codes U.S. Model (2-Door Hatchback) [— Vehicle Identification Number Manufacturer, Maka and Type of Vehicle 2HG: HONDA OF CANADA MFG., INC. HONDA Passenger car Line/Engine and Body Type EH2: CIVIC 1500/2-Door Hatchback EHS: CIVIC 1600/2-Door Hatchback Body and Transmission Type 3:2-Door Hatchback/5-speed Manuel 4:2-Door Hatchback/4-speed ‘Automatic Vobicle Grade ‘4: CX (EH2) 8: VX (EH2) 8: Si (EHS) Check Digit Model Y« N: 1992 Factory Code H: Ontario Factory in Canada Serial Numb [— Vehicle Identification Number and Fi Motor Vehicle Safety Standard Certification [ Engine Number Engine Type. D1587: 1500 SOHC 16-valves injuction (01588: 1500 SOHC 8-valves injuction 70 HP Engine D121: 1500 SOHC 16-valves “Mutti-point Fue!-injuction 90 HP Engine VTEC- 1626: 1600 SOHC 16-valves Muiti-point Fuel-injuction 126 HP Engine VTEC. Emission Group 10: California (01821) 11: California (01626) 12: California (01587, 1588) 13: 49ST (D1521) 18: 49ST (D1587, D16Z6) 16: 49ST (01588) Serial Number [- Transmission Number 24a Transmission Type ——____—— M24A: 4-speed Automatic Transmission $20: B-speed Manual Transmission 1 Number M24a: 1000001~ $20: 1000001~ Se 01587-1000001 1M24A-1000001 [— Paint Code Paint Code Color B-63P Harvard Blue Pear! B-62P Captiva Blue Pearl BG28P Tahitian Green Pearl NH-526M Flint Black Metallic NH-538 Frost White NH-561P Phanton Grey R81 Mirano Red Paint Code COLOR B-63PU.S. Model (4-Door Sedan) [- Vehicle Identification Number JHMEG854*NS000001 Type of Vehicle JHM: HONDA MOTOR CO., ur. HONDA Passenger car IHG: HONDA OF AMERICA MFG. INC. HONDA Passenger car Line/Engine and Body Type EGB: CIVIC 1500/4-Door ‘Sedan EH9: CIVIC 1600/4-Door ‘Sedan Body and Transmission Type ':4-Door Sedan/S-speed ‘Manual 6:4-Door Sedan/4-speed ‘Automatic Vehicle Grac ‘4: DX (EGB) | 5: LX (EG8) 9: EX (EH9) Check Digit Model Yes N: 1992 Factory Code LL Ohio Factory in U.S.A. (East Liberty) 'S: Suzuka Factory in Japan 1 Number [— Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification D1587-1000001 [— Engine Number Engine Type D1887: 1500 SOHC 16-valves Multipoint Fuekinjuction 100 HP Engine D16Z6: 1600 SOHC 16-valves | Multipoint Fuet-injuction 125 HP Engine VTEC. Emission Group 10: California (Suzuka-D1887, D16Z6) 12: California (Ohio-D1887) 13: 49ST (Suzuka-D1887, 01626) 15: 49ST (Ohio-D1887) Sorial Number [- Transmission Number M24A-1000001 M24A-1000001 ‘Transmission Type —_____—] | ‘Automatic Transmission Manual Transmission M24A: 1000001~ 820: 1000001~ [- Paint Code Paint Code Color B-63P Harvard Blue Pearl G-73M Opal Green Metallic NH-526M Black M NH-538 Frost Whi NH-561P Phanton Gray Pear! R-72P Torino Red Pearl R-75P Sonoma Red Rear! YR-503M Rosewood Brown Metallic Paint Code COLOR B-63P. 1-3Chassis and Paint Codes Canada Model (2-Door Hatchback) — Vehicle Identification Number 2HGEH236*NHO00001 | | Manufacturer, Make and ‘Type of Vehicle 2HG: HONDA OF CANADA MFG., INC. HONDA Passenger car Line/Engine and Body Type EH2: CIVIC 1800/2-Door Hatchback EHS: CIVIC 1600/2-Door Hatchback Body and Transmission Type 2-Door Hatchback/S-speed Manual 4:2-Door Hatchback/4-speed ‘Automatic Vehicle Grade 4: CX (EH2) 5: DX (EH2) 6: VX (EH2) 8: Si (EHS) | Check Digit ———_________ Model Year —— N: 1992 Factory Code H: Ontario Factory in Canada Serial Number [— Engine Number. 01887-1700001 ee : 1500 SOHC 16-valves ‘Multi-point Fuel injuction 100 HP Engine D121: 1500 SOHC 16-valves —=-— Multipoint Fuel-injuction 90 HP Engine VTEC-E 1626: 1600 SOHC 16-valves Multi-point Fuel-injuction 126 HP Engine VTEC. Serial Number 01821, 01626: 1700001~ 1587: 1850001~ [— Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification 1-4 [— Transmission Number (M24A-1000001 ‘Transmission Type 1 M24A: 4-speed Automatic Transmission $20: §-speed Manual Transmission Sorial Number M24a: 1000001~ $20: 1000001~ Paint Code Paint Code Color 8-62? Captiva Blue Pearl 8G-28P ‘ahitian Green Peart NH-526M Flint Black Metallic NH-538 Frost White NH-561P Phanton Gray R81 Mirano Red Paint Code COLOR NH-526MCanada Model (4-Door Sedan) (Vehicle Identification Number JHMEG854°NS800001 Manufacturer, Make and i} Type of Vehicle ——— | UHM: HONDA MOTOR CO. U0. HI} HONDA Passenger car | || | Line/Engine and Body Type — EGB: CIVIC 1500/4-Door Sedan | EH9: CIVIC 1600/4-Door Sedan Manual 6:4-Door Sedan/4-speed ‘Automatic Vehicle Grade —— 4: LX (EGB) | 5: EX (EG8) 8: EX-V (EH9) 9: EX-V with ABS and SRS (EHO) Check Digit | Serial Number — | Paint code 01887-1700001 engi Type | 01887: 1500 SOHC 16-valves Multipoint Fuet-injuction 100 HP Engine D16Z6: 1500 SOHC 16-valves | [— Engine Number Mutti-point Fuel-injuction 125 HP Engine VTEC Serial Number (— Transmission Number M24A-1000001 ‘Transmission Type ——___ M24A: 4-speed Automatic Transmission | $20. : 6-speed Manual Transmission Serial Numb 24a: 1000001~ 820: 1000001~ [— Vehicle Identification Number Standard Certification 'S: Suzuka Factory in Japan ae eo B-63P Harvard Blue Peart NH-526M Flint Black Metallic NH-537M Pewter Gray Metallic NH-538 Frost White and Canadian Motor Vehicle Safety RE Paanierley meee R-72P Torino Red Pear! R81 Mirano Red YR-503M. Rosewood Brown MetallicIdentification Number LocationsLabel Locations Warning/Caution Labels A: CABLE REEL CAUTION A CAUTION: [SRS] REFER TO THE SHOP MANUAL B: CABLE REEL CAUTION B [eaunion: [ers] REFER TO THE SHOP MANUAL (C: STEERING WHEEL WARNING WARNING _ [SAS] BEFORE INSTALLING STEERING WHEEL: | © CENTER THE FRONT WHEELS. | © ALIGN THE MARKS. (CABLE REEL) | READ SERVICE MANUAL. D: UNDER-HOOD WARNING WARNING [SRS] THIS VEHICLE IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM. (SRS) ALL SRS ELECTRICAL WIRING AND CONNECTORS | ARE COLORED YELLOW. | DO NOT USE ELECTRICAL TEST EQUIPMENT ON | THESE CIRCUITS. TAMPERING WITH OR DISCON- | NECTING THE SRS WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE ‘THE SYSTEM INOPERATIVE, WHICH MAY RESULT LIN SERIOUS INJURY. (conta 1-7Label Locations - Warning/Caution Labels (cont'd) E: MODULE WARNING 4J: STEERING WHEEL WARNING WARNING [SRI ‘TO PREVENT ACCIDENTAL DEPLOYMENT AND POSSIBLE INguRY: ALWAYS INSTALL THE PROTECTIVE SHORT CONNEC. TOR ON THE INFLATOR CONNECTOR WHEN THE HARNESS 18 DISCONNECTED, UNDER NO CIRCUMSTANCES SHOULD DIAGNOSIS BE PERFORMED USING ELECTRICAL TEST EQUIPMENT OR PROBING DEVICES. NO SERVICEABLE PARTS INSIDE. DO NOT DISASSEMBLE OR TAMPER WITH. STORE THE REMOVED AIRBAG ASSEMBLY WITH THE PAD SURFACE UP. FOR SPECIAL HANDLING OR STORAGE REFER TO THE | HONDA SERVICE MANUAL. | DISPOSE OF THE ENTIRE UNIT AS DIRECTED, | F: DRIVER INFORMATION ‘ALWAYS WEAR YOUR SEAT BELT ‘© THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A | © SUPPLEMENTAL RESTRAINT SYSTEM (SAS). ‘@ ITIS DESIGNED TO SUPPLEMENT THE SEAT BELT. BEFORE DRIVING READ LABEL INSIDE THE CONSOLE BOX G: SAS UNIT CAUTION ‘CAUTION [SRS] ‘© NO SERVICEABLE PARTS INSIDE, | © DO NOT DISASSEMBLE OR TAMPER. ‘® D0 Nor prop. (© STORE IN A CLEAN, DRY AREA. HH: STEERING COLUMN CAUTION ‘CAUTION TO AVOID DAMAGING THE SRS CABLE OR REEL, WHICH COULD MAKE THE SYSTEM INOPERATIVE, REMOVE THE STEERING WHEEL BEFORE REMOVING THE STEERING SHAFT CONNECTOR BOLT. : GLOVE BOX INFORMATION IVER’S AIRBAG INFORMATION (SRS) | © SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CAN | PROVIDE ADDITIONAL PROTECTION FOR THE DRIVER | INA FRONTAL COLLISION. A FUNCTIONAL DESCRIPTION OF THE SRS IS IN YOUR OWNER'S | MANUAL, | (¢ THE SYSTEM MUST BE INSPECTED TEN YEARS AFTER DATE OF MANUFACTURE, AS NOTED ON THE | ‘CERTIFICATION PLATE. | (© ANY REPAIR, INSPECTION OR NEARBY ACCESSORY | INSTALLATION SHOULD BE DONE BY HONDA | DEALER. | ¢¢ IF YOUR sas inpicaToR: | LIGHTS WHILE DRIVING OR FLASHES, + FAILS TO LIGHT OR STAYS ON AFTER THE IGNITION ts FIRST TURNED ON. ‘SEE YOUR AUTHORIZED HONDA DEALER, [Warne [ens] | To PREVENT ACCIDENTAL DEPLOYMENT AND POSSIBLE | insury: ALWAYS INSTALL THE PROTECTIVE SHORT CONNEC- TOR ON THE INFLATOR CONNECTOR WHEN. THE HARNESS IS DISCONNECTED. (ama) K: LABEL, LINFLATOR COVER LABEL DANGER EXPLOSIVE/FLAMMABLE CONTACT WITH ACID, WATER, OR HEAVYMETALS | SUCH AS COPPER, LEAD, OR MERCURY, MAY PRODUCE. | HARMFUL AND IRRITATING GASES OR EXPLOSIVE COM- | POUNDS. STORAGE TEMPERATURES MUST NOT EX. | CEED 200°F(100°C). FOR PROPER HANDLING, ‘STORAGE, AND DISPOSAL PROCEDURES REFER TO THE HONDA SERVICE MANUAL, SRS SUPPLEMENT. | POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE. FIRST AID: | IF CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR EYE CONTACT. FLUSH EYES WITH WATER FOR 15 MINUTES. IF GASES (FROM ACID OR WATER CONTACT) [ARE INHALED, SEEK FRESH AIR. IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. | KEEP OUT OF REACH OF CHILDREN,Lift and Support Points [- Hoist When heavy rear components such as suspension, fuel tank, spare tire and hatch are to be removed, place ‘additional weight In the luggage area before hoisting. When substantial welaht is removed from the rear of the car. the ‘canter of gravity may change and can cause the car to tip forward on the hoist. NOTE: Since each tire/wheel assembly weighs approximately 30 Ibs (14 kg), placing the front wheels in the trunk will ‘assist with the wieght transfer. 1. Place the lift blocks as shown. 2. Raise the hoist a few inches and rock the car to be sure it is firmly supported. 3. Ral the hoist to full height and inspect lift points for solid support. FRONT SUPFORT POINT ur Kooks REAR SUPPORT POINT 1-10r- Floor Jack 1. Set the parking brake and block the wheels that are not being lifted. ‘Always use safety stands when working on or under any vehicle that is supported by only a 2. When lifting the rear of the car, put the gearshift lever in reverse (Automatic in PARK). attompt to use a bumper jack for lifting or ‘supporting the car. 3, Reise the car high enough to insert the safety stands. 4. Adjust and place the safety stands as shown on page 1-10 so the car will be approximately level, ‘then lower the car onto them. Front Center the jack bracket in the middle of the jack lft platform. JACK UFY PLATFORM Center the jack JACK LIFT PLATFORM fof the jack lift platform, cont'd 1-11Lift and Support Points (cont'd) [- Safety Stands FRONT SUPPORT POINT ‘SAFETY’ STANDS. REAR SUPPORT POINTTowing Ifthe car needs to be towed, call a professional towing servic. Nevar tow the car hahind another ear with just ‘rope or chain, It is very dangerous. Emergency Towing ‘There are three popular methods of towing a car: Flat-bed Equipment—The operator loads the car on th back of a truck. This is the best way of towing the car Wheel Lift Equipment—The tow truck uses two pivoting arms which go under the tires (front of rear) and lifts them off the ground. The other two wheels re- ‘main on the ground, Sling-type Equipment—The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension and the cables lft that tend of the car off the ground. The car's suspension and body can be seriously damaged if this method of towing is attempted. If the car cannot be transported by flat-bed, it should be ‘towed with the front wheels off the ground. If due to ‘damage, the car must be towed with the front wheels ‘on the ground, do the following: © Release the parking brake. © Shift the transmission to Neutral (5-speed). If the car has an automatic transmission: Start the engine, Shift to De, then to Neutral. Shut the engine off. NOTICE: Improper towing preparation will damage the transmission. Follow the above procedure exact: ly. If you can not shift the transmission or start the engine (automatic transmission), the car must be transported on a flat-bed. Iris best to tow the car no farther than 60 miles (80 km), and keep the speed below 35 mph (55 kg/h]. NOTICE: Trying to lift or tow the car by the bumpers will cause serious damge. The bumpers are not d signed to support the car's weight, Front: CAUTION: On the car equipped with the front spoiler, remove the spoiler when towing. ‘Tow HOOK 1-13Special Tools Individual too! lists are located at the front of each section.Specifications Standards and Service Limits .. Design Specifications Body Specifications .. . 3-14 - 3-17Standards and Service Limits ;- Cylinder Head/Valve Train — Section 6 MEASUREMENT STANDARD (NEW) SERVICE LMT Com | 250 rom and Nominal 7,300 113.0,188) pression | wide open throttle Minirnarn 980 19.5,138) ea tkalem, psi Maximum variation | 200 (2,28) Cylinder == | 0.08 (0.002) heed 01687, 01588 | 94.95-95.05 (3.738-3.742) | — 1821, 01626 | 92.95-93.05 (3.659—3.663) | — Camshaft 0.05-0.18 (0.002-0.006) 0.5 (0.02) 0.050 0.089 (0.002~0.004) | 0.15 (0.006 Runout 0.018 (0.0006) mex. 0.03 (0.0011 Cam lobe Height 01587 IN 36.957 (1.48550) — x 36.996 (1.4565) — 01886 IN 39.087 (1.4196) = x 36,198 (1.4251) — 1821 IN Primary | 38.427 (1.5129) = Secondary | 32.292 (1.2713) = x 37.997 (1.4959) — 1626 IN Primary | 35.900 (1.4134) = Mi 38.107 (1.5003) = Secondary | 36.195 (1.4250) —_ x | 58.008 (1:4964) = Valve | Valve clearance IN | 0.18~-0.22 (0.070.008) = &X| 0.23-0.27 (0.008-0.011) — Valve stem 0.0. IN | 5:48-8.49 (0.2187-0.2161) _| 5.45 (0.2183) ex] 5:45~5.46 (0.2146-0.2180) —_| 6.42 (0.2134) Stemto-guide clearance IN| 0.0200.08 (0.0008-0.0020) _| 0.08 (0.003) EX | 0.05~0.08 (0.020.003) 0.42 (0.008) Valve | Width IN | 0.85—1.18 (0.030.048) 7.6 (0.083) seat &x| 1.25— 1.55 (0.049-0.061) 2.0 (0.078) Stem installed height 01867, 1588 IN | 46,985—-47.485 (1.8498—1.8683)| 47.705 (1.8781) ex | 48.965— 49.435 (1.9276 1.9463) | 49.685 (1.9561) 01821, 01626 IN | 53.165—69.696 (2.0991 —-2.1116)| 63.885 (2.1215) &x | 53,165~53.635 (2.0931 ~2.1116) | 83.885 (2.1215) Valve Tength 1687 IN | 61.90 (2.0433) *1 — spring | 51.88 (2.0425) +2 = &X| 58.28 (2177) °1 = | San ive) +2 = 1688 ww | 48.58 (1.913) — ex| 55.28 (2.178) — D182z1 IN | 54.78 (2.187) 84.02 (2.127) ex| 58.23 (2.283) *1 0.26 (20d “2 } s72a2207 o16z6 ww | 87.97 (2.282) 56.95 (2.243) &X | 68.41 (2.300), 57.38 (2.217) Vave | 10. WW | §.51~8.69 (0.217.218) 5.60 (0.220) auide ex| 5.51~5.53 (0.217-0.218) 5.60 (0.220) Instaled height 01887, 01688 IN | 15.95~16.45 (0.628--0.648) | — &x| 15.95—16.45 (0.628-0.648) | — 01821, 01626 IN | 17.85-18.35 (0.703-0.722) | — ex] 18.65-19.15 10.734-0.754) | — Rocker | Arm-to-shalt clearance IN | 0.017-0.080 10.0007—-0.0020) | 0.08 (0.008) am &x | 0.018-0.054 (0.00070.0021)_| 0.08 (0.003) 71: NIPPON HATSUJO made, *2: CHUO HATSUJO made. 3-2[- Engine Block — Section 7 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) SERVICE LIMIT Cylinder | Wapage of deck surface (0.07 (0.003) max (0.10 (0.004) block | Bore diameter 78.00-78.02 (2.983—2.954) 78.07 (2.956) Bore taper — 0.08 (0.002) Reboring limit = 0.5 (0.02) Piston | Skirt [é 1D1587/018B8: 16 mm (0.63 in), ] 74.98—74.99 (2.9820-2.9524) | 74.97 (2.9516) 0.0. | 1521/1628: 15 mm (0.589 in) from bottom of skirt Clearance in cylinder 0.01 -0.04 (0.0004—0.0016) 0.05 (0,002) Groove width (for ring) Top 1,221.23 (0.0480—0.0484) 1.25 (0.049) Second 01821 1.22~1.23 (0.0480—0.0484) 1.25 (0.049) Except 01821 | 1.52—1.83 (0.0598—0.0602) 1.55 (0.061), oi 2.805—2.820 (0.1104—0.1110) _| 2.85 (0.112) Piston | Ring-to-groove Top Di6zi (0.030-0.055 (0.0012-0.0022) | 0.13 (0.005) ring clearance Except D121 | 0.035-0.060 (0.0014-0.0024) | 0.13 (0.008) _ ‘Second 0.035—0.085 (0.0014—0.0022) | 0.13 (0.005) Ring end gap Top (0.18 0.30 (0.006-0.012) | 0.60 (0.024) ‘Second 0.30-0.45 (0.012~0.018) | 0.70 (0.028) oi 0.20~0.70 (0.080.028) 0.80 (0.031) Piston Pin] 0.0. 18.994— 19.000 (0.7478—0.7480)| —— Pin-to-piston clearance 0.010-0.022 (0.0004—0.0009) | — Connect: | Pin-to-rod interference '0.014—0.040 (0,0006—0.0016) | —— ing red | Small end bore diameter 18,96- 18.98 (0.746-0.747) | — Large end bore diameter Nominal D158 48.00 (1.89) — Except D1588 | 45.00 (1.77) — End play installed on crankshaft 0.18-0.30 (0.006-0.012) | 0.40 10.016) Small end bore-to-large end bore parallelism 0.12 (0.0081/100 max. 0.18 (0.006/100 Crank- | Main journal diamet p16z6 54.976—-55,000 (2.1644—2.1654) | — shaft Except 1626 | 44.876—45.000 (1.7707—1.7717)| — Rod journal diameter 44,876 —45.000 (1.7707—1.7717)|, — Taper 0.0028 (0.0001) max. 0.01 (0.0004) Our-of round 0.0028 (0.0001) max. 0.01 (0.0004) End play 0.100.385 (0.004—0.014) 0.45 (0.018) Runout 0.018 (0.0006) max. 0.03 (0.0012) Bearings | Main bearing-to-journal No. 1 and 6 journals | 0.018-0.036 (0.0007—0.0014) | 0.08 (0.002) Oil clearance No. 2, 3 and 4 journals | 0.024—0.042 (0.0010-0.0017) | 0.05 (0.002) Rod bearing-to-journal oil clearance 0.020-0.038 (0.0008-0.0014) _| 0.05 (0.002), 3-3Standards and Service Limits [- Engine Lubrication — Section 8 MEASUREMENT | STANDARD (NEW) SERVICE LIMIT Engine ol'| Capacity ¢ (US qr, Imp qu 4.0 (4.2, 3.8) for engine overhaul | 3.3 13.5, 2.9) for oil change, including fiter il pump | Displacement ¢ (US gal, Imp gallimin @rpm | 45.0 (11.89, 9.90) @6,000 Inner-to-outer rotor clearance 0.02-0.14 (0.001-0.008) 0.2 (0.008) Pump body-to-outer rotor clearance 0.100.175 (0.004—0.007) 0.2 (0.008) Pump body-to-rotor axial clearance 0.03-0.08 (0.001 0.003) 0.18 (0.008) Relief | Pressure setting 80°C (176°F) at idle 70 (0.7, 10) min. valve _| kPa ifkg/cm?, psi) at 3.000 rom | 350 (3.5, 60) min. [- Cooling — Section 10 MEASUREMENT | STANDARD (NEW) Radiator | Coolant capacity (US gal, imp gal) D16Z6 | M/T: 4.8 (1.12, 0.99) for overhaul including engine, heater, cooling 3.6 (0.96, 0.79) for coolant change ine and reservoir AMT: 4.7 (1.16, 1.03) for overhaul reservoir capacity: 3.8 (1.00, 0.84) for coolant change 0.4 ¢ (0.42 US at, 0.35 Imp at) 01587 | MIT: 4.5 (1.12, 0.99) for overhaul 3.6 (0.95, 0.79) for coolant change AIT: 4.4 (1.08, 0.97) for overhaul 3.5 (0.92, 0.77) for coolant chenge 1821 | MIT: 4.4 (1.08, 0.97) for overhaul 3.5 (0.92, 0.77) for coolant change 01588 | MIT: 4.5 (1.12, 0.99) for overhaul 3.6 (0.95, 0.79) for coolant change Radiator cap| Opening pressure kPa (kg/cm, psi) 95—126 (0.95—1.26, 13.6-17.8) Thermostat] Start to opening °C( °F) D1SZ1 80-84 (176-183) Except D1521] 76-80 (169-176) Fully open °C (°F) 1821 95 (203), Except 01821) 90 (194) Valve lift at fully open 8.0 10.31) min. Wter pump | Displacement ¢ (US gal, Imp gallimin @rpm | 125 (83.0, 27.5) @6,000 Cooling | Thermoswitch “ON" temperature °C (°F) | 91.0—95.0 (196-203) fan Thermoswitch “OFF temperature °C (_°F) | Subtract 3-8 (5—15) from actual “ON” temperature.[— Fuel and Emission — Section 11 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) Fuel pum] Displacement ce (US oz, Imp oz) n 10 seconds| 222 (7.6, 7.8) min Relief valve opening pressure” kPa tkglcm®, ps) | 90 (3.0, 43) Pressure | Pressure with regulator vacuum hose 7 regulator | disconnected kPa (kg/cm?, psi) 2S Same Fuel tank | Capacity _¢ (US gal, Imp gel) 451119, 88) Engine | Idle speed rpm Mt ant with healight ane USA | Canada| USA | Conade ° | 01887 670 | 750 700 (N) 750 (N} | bree | 670 | yo | OY | RM | piszr | soo | 700 = oreze | 670 750 | 700 | _750.N) Tale CO 0.4 max ;- Clutch — Section 12 | MEASUREMENT STANDARD (NEW) ‘SERVICE LIMIT Giuich | Pedal height wotloor | 164 16.4) — pedal | Stroke 1356.3) | — Pedal play 12-21 (0.5-0.8) = Disengagement height to floor | 8918.3) — to carpet | 55 (2.2) min. Reference = Fiywheel | Clutch surface runout (0.06 (0.002) mex 0.18 (0,006) Cutch | Rivet head depth 1.3 (0.06) max. 0.2 (0.008 dis | Surface runout 018 (0.03) max. 110 (0.04, Thickness 8.18.8 (0.32-0.36) 8.7 (0.22, Clutch | Pressure plate warpage 0.08 (0.001) max 0.16 (0,006)Standards and Service Limits [— Manual Transmi ion — Section 13 MEASUREMENT ‘STANDARD (NEW) |_ service unit Trenwinis| Capacity €(U.S.at, Wpagt) 78 (1.9, 1.6) ot oll change sion oil | 1.9 (2.0, 1.7) at assembly ‘Mainshaft| End play '0.13—0.20 (0.005—0.008) ] Adjust with shim Diameter of ball bearing contact area 28.977--28.990 (1.0227 1.0232) | 25.92 (1.020), {clutch hosing side) } Diameter of third gear contact area 33.984—34.000 (1.3380— 1.3386) | 33.93 (1.336) 26.980—26.993 (1.0622— 1.06271 26.93 (1.060) 21.987—22.000 (0.8656—0.8661) | 21.93 (0.863) Diameter of 4th, 5th gear contact Diameter of ball bearing contact {transmission hosing side) | Ronout 0.02 (0.0008) max. 0.08 (0.002) Mainshafi| 1.0. 39,009-39.026 (1.6358— 1.5368) | 39.07 (1.538) third and_| End pl 3rd__| 0.08-0.21 (0.0024-0.0083) | 0.33 10.013) fourth atm | 0.08-0:19 0.0024-0.0078)__| 0.31 10.012, gears | Thickness aed | $0:22~30.27 (1.1898-1.1917) -| 30.18 (1.187) 4in_| 30:12—30.17 (1:1868—1:1878)_| 30.08 (1.183) Mainshaft| 10, 7.008-37.026 (1.4570—1.4877)| 37.07 (1.459) fith gear | End play 0660.19 (0.0024~0.0078) | 0.31 10.612) Thickness 28,42~28.87 (1.1189—1.1209)_| 28.35 (1.116) Counter- | End play 0.17-0.38 (0,0067—0.0160) | 0.83 (0.021) shaft. | Diameter of needle bearing contact area 30,000--30.0165 (1.1811~1.1817)| 29.98 (1.179) Diameter of bal bearing contact area 24.980 24.993 (0.9835—0.9840) | 24.93 (0.981) Diameter of low gear contact area 36,984— 36,000 (1.4167—1.4173)| 35.93 (1.418), Runout 0.62 (0.0008) max 0.95 10.602) Counter. | 10. “1,009—41.0265 (1.6145—1.6182)| 41.07 (1.617) shaft low | End play 0.03-0,10 (0.0012—0.0038) | 0.32 10.009), gear | Thickness 30,130.44 (1.1972—1.1984)_| 30.36 (1.196) Counter | 1.0: ‘44,009—44.025 (1.7326—1,7350)| 44.07 (1.738) shaft se- | End play 0.03-0.11 (0.0012~-0.0043) | 0.23 (0.009) ond gear| Thickness 31,92~31.97 (1.2867—1.2587)_| 31.85 (1.254) Spec colt | 1D. ‘32,988 -32.998 (1.2987—1.29971| 33.04 (1.301) (Camendet | 0.0. 381989 39.000 (1.5360 1.5386) | 38.99 (1.533) sens ee! | Length 32103~32.06 (1.2610 1.2622) _ | 32.01 (1.260) Spacer cor] 10. 27.002—27.0%2 (1,0631 —1.0836)| 27.06 (1.085) iartMon | 0.0. ain | 321989 34.000 (1/3381 1.3386) | 39.99 (1.336) shaft Sth | 31/989—32.000 (1,2694— 1.2898) | 31.93 (1.257) fourth and | Length ath | 22:83-22.86 (0.8988—0.9000) | 22181 10.890) 7 Sth__| 23°53—29°56 (0.9264—0.9276)_| 23.51 (0.926) 1, 75.016~ 16.083 (0.6971 -0.6023) 16.08 (0.694) Idler gear | Geor-to-reverse gear shaft clearance 0.032--0.077 (0.0013~0.0030) | 0.14 (0.008) Synchro rng] Ringto-gear clearance (ring pushed 0.73~1.18 (0,028-0.046) | 0.4 (0.016) Shift fork | Shift fork finger thickness 64-65 (0.252—0.256) — : wk-to-synchro sleeve clearance 0:25~0.48 (0,0098-0.0177) __| 0.8 10.03) everse ork paul groove width 12.7=13.0 (0.600-0.512) | — shift fork | Forkto-revers idler gear clearance 08-1.1 (0.020-0.043) | re 10.07 Groove width 7.08--7.28(0.278-0.285) | —— Fork-to-fithireverse shift piece pin clearance | 0,050.35 (0.002—0.014) 05 (0.02) Shift arm | Diameter of shift rod contact area 13.006- 13,190 (0.5120—0.6169)/ — A Shift arm Acto-shift od clearance 0.005~0.230 (0.0002—0.0081) _| 0.35 (0.0138) Shift arm | Diameter of shift arm sheft contact area 13,973 14.000 (0.6601-0.8612] — 8 Shift arm B-to-shift arm shaft clearance 0.613~0.070 (0.0005~-0.0028) | 0.16 (0.0083) Shift arm B-to-shift piece clearance | 0.20.8 10.0079-0.0197) 0.62 (0.0244) Shift piece diameter of shift fork shaft | contact area 12.9-13.0(0.5079-0.5118) _| 12.78 (0.6031)( Automatic Transmission — Section 14 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) |_ Service Lin Transmis-| Capacity (US qt, Imp qt) 6.9 (6.2, 5.2) for overhaul ~ sion fluid 2:7 (2.8, 24) for fluid change Hydraulic | Line pressure at 2,000 rom N or P 850-900 (8.59.0, 121-128) | 600 18.0, 114) 2nd clutch pressure at 2,000 rpm De ‘400 (4.0, 67) | 350 (3.5, 50) thvottle fully closed | hott Fy — aoe 1 closed 3rd clutch pressure at 2,000 rpm D. exonso0 es-90, 121-120 | throttle more than 1/8 ope 800 18.0, 114) “th clutch pressure at 2,000 rpm Ds | throtie more | than 1/8 opened 2nd clutch pressure at 2,000 rpm 2 850-900 (8.68.0, 121-126) | 8018.0, 114) 1st clutch pressure ot 2,000 rpm De or 1 850—900 (8.5—9.0, 121-128) | 800 18.0, 114) Governor pressure Diez6 180—190 (1.80-1.90, 25.6-27.0) | 175 (1.75, 24.9) at 37.5 mph (60 kmh) Except 1626 | 182-192 (1.82-1.92, 25.9-27.9) | 177 (1.77, 26.2) Throttle pressure B Throttle fully closed | 0-16 (0—0.16, 02.1) | | Throtte fully open | 850-900 (8.59.0, 121-128) _| 800 (6.0, 114) _| [Throttle pressure A Throttle fully closed | O—§ (0—0.05, 0—0.7) |— Lioreze) Throttle fully open | 515~530 (6.15.3, 73.2~75.4) | 510 (5.1, 72.5) [Throttle pressure A Throttle fully closed | 0-5 (0-0.05, 00.7) — ___| except 01628) Throttle fully open | 505~520 (5.05—6.2, 71.8—73.8) | 500 (5.0, 71.1) Stall speed rpm (check with car on level ground) 2,600 | 2,400—2,800 Clutch — | Clutch initial clearance Ast, 2nd 0.65—0.86 (0.026—0.033) | 3rd, 4th | 0.40-0.60 (0.016-0.024) — | clutch return spring free length Tat 31.0 (1.22) 29.01.14) 2nd, 3x6, 4th | 30.5 (1.20) 28,5 (1.12) | Iethold | 34.6 (7.36) 3216 (1.28) | Clutch disc thickness 1.88—2.00 (0.074—0.079) Until grooves: worn out | Clutch plate thickness 1st 1,851.66 (0,081 0.088) Discoloration Except 1st_ | 1.95~2.05 (0.077—0.081) Discoloration Clutch end plate thickness MARK 1 | 2.32.4 (0.091—0.094) Discoloration texcept tsthold) MaaK 2. | 2.42.5 (0.084—0.098) MARK 3 | 2.52.6 (0.080.102) | MARK 4 | 2.62.7 (0.102—0.106) Mark 5 | 2.72.8 (0.106-0.110) MARK 6 | 2.8-2.9 (0.100.114) mark 7 | 2:9-3.0 (0.114—0.118) MARK 8 | 3.03.1 (0.118—0.122) Mark 9 | 3.13.2 (0.122.126) MARK 10 | 3.2~3.3 (0.126-0.130) MARK 11 | 2.0~2:1 (0.079-0.083) MARK 12 | 21-2:2 (0.083-0.087) MARK 13 | 2.22.3 (0.087—0.091) Discoloration Clutch end plate thickness MARK 1 | 2,05~2.10 (0.081-0.083) Discoloration (isthold) Mark 2. | 215~2.20 (0.085-0.087) mark 3. | 2.25~2.20 (0.890.091) MARK 4 | 2.35-2.40 (0.093-0.094) NO MARK| 2.48250 (0.096—0.098) MARK 6. | 2.55—2.60 (0.1000. 102) MARK 7_| 2.65~2.70 (0.108~0.106) Discoloration teont’d) 3-7Standards and Service Limits [- Automatic Transmission (cont'd) — Section 14 MEASUREMENT | STANDARD (NEW) SERVICE LIMIT Trane: Diameter of needle bearing contact a ‘On mainshaft and stator shaft ‘On mainshaft 2nd ge: ‘On mainshatt 4th gear collar ‘On mainshaft 1st gear collar ‘On countershaft (L. side) ‘On countershaft 3rd gear distance collar ‘On countershaft 4th ge ‘On countershaft reverse gear collar On countershaft 1st gear coll ‘On subshaft (L. side) ‘On subshaft 4th gear collar ‘On reverse idler gear shaft ‘On mainshatt 1st g (On mainshaft 2nd ‘On mainshaft 4th gear On countershaft 1st get Inside diameter of needle bearing contact area (On countershatt 3rd gear On countershaft 4th gear On countershaft reverse gear On subshaft 4th gear On reverse idler gear On stator shaft (R. side) On stator shaft (stator side) On reverse idler shaft holder End play | Mainshatt 1st gear | Mainshatt 2nd gear Mainshaft 4th ge: Countershaft 1st gear Countershaft 3rd gear Countershaft 4th gear Subshaft 4th gear Reverse idler g Countershaft reverse gear Selector hub 0.D. Mainshaft 4th gear collar length Mainshaft 1st gear collar length Mainshaft 1st gear collar flange thickness 0.05~0.13 (0.002~ 45.00—48.03 (1.772—1 27.00~27.15 (1.063~1 22,980-22.998 (0.9047—0.9052) 35.975—36.991 (1.4163— 1.4169) 31.975~31.991 (1.2589— 1.2595) 30.975 ~30.991 (1.2195~1.2201) 36.004-36.017 (1.4175—1.4180), 31.975—31.991 (1.2589— 1.2595) 27.980~27.993 (1.1016—1.1021) 31.975 31.991 (1.2589— 1.2595) 31.975—31.991 (1.2589 1.2595) 25.991 —26.000 (1.0233— 1.0236) 27.980~27.993 (1.1016—1.1021), 13.990~ 14.000 (0.8508—0.5612) 38.000—35.016 (1.3780— 1.3786) 41.000—41.016 (1.6142— 1.6148) 38.000-38.016 (1.4961 — 1.4987), 38.000~38.016 (1.4961 ~1.4967) 38.000-38.016 (1.4961 —1.6967) 33.000-33.016 (1.2992— 1.2998), 38.000-38.016 (1.4961 —1.4967), 32.000—32.016 (1.2598 1.2605) 18.007 18.020 (0.7089—0.7094) 29.000~29.013 (1.1417~1.1422), 27.000~27.021 (1.0630~1.1638) 14.416— 14.434 (0.6676—0.6683) 0.08 0.24 (0.030.008) (0051) 0.05—0.135 (0.002—0.0053) 0.10.5 {0.004—0.020) 0.05-0.13 (0.002—0.0051) 0.05~0.13 (0.002—0.0051) 0.05—0.17 (0.020.007) 0.05—0.18 10.002—0.007) 0.10-0.25 (0.004—0.010) 51.87—51.90 (2.042~2.043) 773) 069) Wear or damage Wear'or damage Wear or damage Wear'or damage HTT Wear or damage Wear or damage Countershaft distance collar length ‘Countershaft reverse gear collar length Countershaft reverse gear collar flange thickness Countershaft 1st gear collar length Countershaft 1st gear collar flange thickness Subshaft 4th gear collar length Subshatt 4th gear collar tlange thickness 38.97 39.00 (1.534—1 39.02-39.05 (1.536—1 39.07—39.10 (1.538—1 39.12~39.15 (1.540—1 39.17-39.20 (1.542—1 39,22~39.26 (1.544—1 39.27-39.30 (1.546—1 38.92~38.95 (1.532-1 2.4—2.6 (0.084~0.102) 14.5. 2.4~2.6 (0.084—0.102) 38.87—38.90 (1.5301. 2.5~2.6 (2.098 2.102) 535) 537) 539) 541) 543) 545) 847) 531) 1533) 14.8—14.6 (0.871 0.875) 14.6 (0.571 0.575) | 24.0-24.1 (0,945—0.949) 3.00—3.15 10.118-0.124) HITE Wear or damage Wear or damage Wear or damage Wear or damaUnit of length: mm (in) [- Automatic Transmission — Section 14 * (MEASUREMENT STANDARD (NEW) ‘SERVICE LIMIT Transmis-| Mainshaft 2nd gear thrust washer thickness 3.47—3.60 (0.137—0.138) Wear or damage sion 3.52—3.55 (0.139-0.140) (cont'd) 3,573.60 (0.141 —0.142) 3.62—3.68 (0.143-0.144) 3.67—3.70 (0.145-0.148) 3.72-3.78 (0.147~0.148) 3,773.80 (0.148—0.160) | 3.82—3.85 (0.151—0.152) | 3.87—3.90 (0.153~0.154) | Wearlor damage | | Thrust washer thickness Mainshaft 4th gear 4.45—4.85 (0.175-0.179) Wear or damage Mainshatt bal bearing L. side 3.45 -3.56 (0,196—0.140) Mainshatt 1st gear L. side 1.41.80 (0.067—0.087) Mainshatt 1st gear side 3.43—3.60 (0.135—0.138) Weal or damage Mainshaft 3rd gear thrust washer thickness 2,873.00 (0.117-0.118) Wear or damage 3.02—3.05 (0.119-0.120) | 3.07—3.10 (0.121-0.122) | | 3:12-8.18 (0,123-0.124) 3.17=8,20 (0,125—0.126) 3.22—3.25 (0.127-0.128) 3:27-3,30 (0,128-0.130) | 3.32—8.96 (0,191—0.132) | 3.37—3.40 (0.133-0.134) , 3.42—3.45 (0.135—0.136) Wearlor deme Mainshaft 4th gear thrust washer thickness 2.83-3.00 (0.118 0.118) Wear or damage One-way clutch contact area I.D. Countershatt 1st gear 83.939-89.965 (9.2810-3.2821)| Parking gear 66.685 66.698 (2.6264—2.6258) | Wear"or damage Mainshatt feed pipe A, 0.0. 8.97-8.98 (0.353-0.354) 8.95 (0.352) Mainshatt feed pipe B, 0.0, 5,976.98 (0.2350-0.2954) | 5.95 (0.234) Countershatt feed pipe 0.0 | 7.97—7.98 (0.3138-0.3142) | 7.95 18.313) Subsheft feed pipe 0.0. 797-7.88 (0.3138-0.3142) | 7.95 (0.313) Mainshaft sealing ring thickness 1.980 1.995 (0.0780-0.0785) | 1.80 (0.071) (28 mm end 36 mm) Mainshaft bushing 1.0. 6.018-6.030 (0.2869-0.2374) | 6.045 (0.2380) Mainshaft bushing I.D. 8,000-9.018 (0.3543—0.9549) | 9.030 (0.366) Countershaft bushing ID 8.000-8.015 (0.3160—0.9156) | 8.030 0.9161) Subshaft bushing .D. 8,000-8.016 (0.3160—0.3156) | 8.030 (0.3161) Mainshatt sealing ring groove width 2.025~ 2.060 10.0797—0.081) _| 2,080 (0.082) Regulator | Sealing ring contact .D. '35.000—35.025 (1,3780—1.3782)| 36.050 (1.3799) valve body Sting | Reverse shift fork finger thickness 5,806.00 (0.232-0.236) 5.40 10.213) Aevice and_| Parking brake ratchet paw! — Wear or paring _| Parking broke gear — other detect brake convo) Throttle cam stopper height 27.0-27.1 (1.063-1.087) = Serve | Shift fork shaft bore LD. 14.000—14.010 (0.6612-0.8616)| — body _| Shift fork shaft valve bore 0, 37.000 37.038 (1.4567— 1.4582)| 97.045 (1:4585) Oi! pump | Oil pump gear side clearance (0.030.085 (0.001 ~0.002) 0.07 (0.003) Oil pump geor-to-body clearance Drive | 0.210-0.265 (0.0083-0.0104) | — Driven | 0.070~0.125 (0,0028-0.0049) | | — it pump driven gear 0. 14.016 14.034 (0.5518--0.5526) | Wear or damage Oil pump shaft 0.0. 19,980 13,000 (0.6604—0.5608) | Wear or damage {cont’a) 3-9